Lincoln Electric IM610-A manual GUN and Cable Maintenance, For Magnum 100L GUN

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D-2

MAINTENANCE

D-2

GUN AND CABLE

MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable Cleaning

Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end.

CAUTION

Excessive pressure at the start may cause the dirt to form a plug.

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out.

Contact Tips, Nozzles, and Gun Tubes

1.Dirt can accumulate in the contact tip hole and restrict wire feeding. After each spool of wire is used, remove the contact tip and clean it by push- ing a short piece of wire through the tip repeatedly. Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip.

2.Replace worn contact tips as required. A variable or “hunting” arc is a typical symptom of a worn con- tact tip. To install a new tip, choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.

3.Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.

4.Be sure the gas nozzle is fully screwed onto the

diffuser for gas shielded processes. For the Innershield® process, the gasless nozzle should be screwed onto the diffuser.

5.To remove gun tube from gun, remove gas nozzle or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place against the gun end cable connector. Unscrew gun tube from cable connector. To install gun tube, screw the locking nut on the gun tube as far as possible. Then screw the gun tube into the cable connector until it bottoms. Then unscrew (no more than one turn) the gun tube until its axis is perpendicular to the flat sides of the cable connec- tor and pointed in the direction of the trigger. Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and dif- fuser. Replace the gas nozzle or gasless nozzle.

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM

 

Contact Tip

Cable Liner

Drive Roll

 

 

 

 

 

 

 

Components shipped with

S19726-1(In Gun)

M16291-5

M15448

 

 

 

SP-175 Plus

.025” (0.6mm)

.030-.035”

2 Smooth grooves

 

S19726-2&-3(Loose)

(0.8-0.9 mm)

Small .023-.025” (Stenciled .025)

 

.030” & .035”

 

Large .030-.035” (Stenciled .030-.035)

 

 

 

 

K549-1 .035” (0.9mm)

S19726-3

M16291-6

Use Large groove

Innershield Welding Kit

.035” (0.9mm)

.035” (0.9mm)

KP666-035

 

 

 

 

K549-4 .045 (1.2 mm)

S19726-4

M16291-1

M15448-2 .035/.045”

Innershield Welding Kit

.045” (1.2mm)

.045” (1.2mm)

Dual groove both sides

 

 

 

 

 

K663-2 .035”

S24221-1

M18971-1

S24220

.035-3/64” (drive roll

Aluminum or Stainless Kit*•

.035A” (0.9mm)

.045” (1.2mm)

S24219

(idle roll)

 

 

 

 

 

 

 

KP666-035C

 

 

M15448-1

 

 

 

2 Knurled grooves for .035” (0.9mm)

 

 

 

 

 

 

 

• If .030 Solid wire feeding is desired obtain an S19726-2 Contact Tip, an M16291-2 Cable Liner and an M15448 Drive Roll (Smaller Groove).

*It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure to do so may result in contaminated welds when welding aluminum.

SP-175 PLUS

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Contents SP-175 Plus Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a LʼArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Installation Safety Precautions Read entire installation section before startingInstallation Identify and Locate ComponentsWork Clamp Installation Work Cable InstallationSelect Suitable Location StackingGUN Installation Connecting Gun Cable to the SP-175 PlusGAS Connection Gas Solenoid Inlet Fitting Power Input Cable Input ConnectionsLine Cord Connection Electrical Input Connection for Rated OutputVolt Input Connection Observe all safety information throughout this manual OperationFumes and Gases can be dangerous Welding Sparks can cause fire or explosionControls and Settings Design Features AdvantagesGeneral Description Welding CapabilityWire Loading Welding OperationsSequence of Operation Friction Brake Adjustments Wire ThreadingShielding Gas Making a WeldChanging Machine Over to Feed Other Wire Sizes Cleaning Tip And NozzleProcess Guidelines Wire Feed Overload Protection Overload ProtectionOutput Overload Thermal ProtectionLearning to Weld Learning to WeldARC-WELDING Circuit SELF-SHIELDED Fcaw Welding ARCGmaw MIG Welding ARC Process SelectionFor Gmaw MIG Process Common Metals Joint Types and PositionsFor Fcaw Innershield Process Butt WeldsWelding In The Vertical Position PenetrationFillet Welds Machine SET UP for the SELF-SHIELDED Fcaw Process Welding Techniques for the Self Shielded Fcaw ProcessVertical-down Welding Correct Welding PositionCorrect Electrical Stickout ESO Correct Welding SpeedHelpful Hints PracticeMachine SET UP for the Gmaw MIG Process Welding Techniques for the Gmaw MIG ProcessFigure B.24 Troubleshooting Welds To Correct Poor Penetration in order of impor- tanceTo Eliminate a Ropy Convex Bead in order of importance To Eliminate Stubbing* in order of importanceProper Gun Handling Application Chart Accessories Optional Accessories K1799-1 Argon-Mixed Gas Adjustable Regulator and Hose Kit K586-1 Deluxe Adjustable Gas Regulator Hose KitReplacement Parts Innershield Fcaw ConversionMaintenance Maintenance Safety PrecautionsItems Requiring no Maintenance Routine and Periodic MAINTE- NanceGUN and Cable Maintenance Configuration of Components in Wire Feeding SystemFor Magnum 100L GUN Contact Tip Cable Liner Drive RollChanging the Contact TIP Changing Drive RollRoll onto the drive shaft SP-175 Plus Changing Liner Liner trim lengthGUN Handle Parts Figure D.3 SP-125 PlusTroubleshooting HOW to USE Troubleshooting GuideProblems Possible Areas Symptoms Misadjustments Recommended Course of ActionGAS Flow Problems Welding Problems Wiring Diagrams SP-175 Plus Wiring Diagram CodePage How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? $700.00Precaucion Warnung
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